Assembly of profiles for sustaining, molding and finishing the concrete of slab, beam and column

ABSTRACT

A set of extruded profiles for the construction of slabs, beams and columns, which are assembled in a systematic manner and have the function of covering the slab, column and beam, eliminating the need for any finishing, and has the function of serving as to receive the concrete during construction. The constructive arrangement of the parts forming said set of profiles and allowing their assembly in a systematic manner, guarantees numerous functional advantages, as well as in their use and is comprised of five extrusion profiles, preferably PVC, not limited to this material, comprising a main plate, a filling profile, which will replace the Styrofoam block, and three profile variations for column construction.

This report presents a set of extruded profiles for the construction ofslabs, beams and columns, which are assembled in a systematic manner.Such a set of profiles has the function of covering the slab, column andbeam, and has the function of serving as a form to receive the concreteduring construction. The constructive arrangement of the parts formingthe said assembly and allowing its assembly in a systematic manner,guarantees numerous functional advantages, as well as in its use.

The construction of slabs, beams and columns is already of technicalknowledge, using blocks of Styrofoam as a fill, to leave the slablighter and using box and building irons; in this traditional process,after the assembly of the box—as the molds that hold the concrete arecalled until it solidifies—the Styrofoam blocks are arranged and thelattice beams or concrete beams are assembled, and then the concrete ispoured into the box until it will harden and the casing be removed;after removal, the plaster is made to finish. The construction of theslabs in particular is slow and requires intense physical effort of theworker, especially in the assembly of lattice beams and the finishing ofthe lower part of the slab, knowing that in the latter, the worker mustsprinkle cement from the bottom up, which in addition may cause damageto the operator's physical integrity.

In order to increase the practicality and speed in the construction ofslabs, some improvements have been developed, focusing on the solutionof some specific problem, as shown in document MU8802069-0 that presentsa form of brick in thermoplastic to be used in slabs; and documentMU9001782-0 which shows an improvement in the construction of latticegirder beams. Also, document BR102012012581-1 that presents a form ofconstruction of slab without finishing, but with proposal totallydifferent from the one that this report refers, mainly because it is thefield of the ribbed slabs.

Other patentable priorities which may be cited are the documentsBR202015008514-7, which has a constructive profile shape, which presentsgreater mechanical resistance by distributing the internal stresses tothe profile, at the time of concreting and drying the concrete; andCA2097226, which also provides a form of wall construction by means ofthermoplastic profiles, which aim to simplify the obtaining of thebuilding, providing finished walls after the pouring of the concreteinto the profiles.

Based on the known state of the art, little has been changed in thetraditional slab construction process, and some minor improvements haveoccurred in some processes. Nowadays, little has been altered in theconstruction of the foundation of a building, mainly of residences andsmaller buildings. The process consists of assembling the column caseand iron structure, then the concrete is poured; as soon as it hardensthe construction of the beams and slab begins. The slab is commonlyfilled with blocks of Styrofoam between the lattice beams, with thepurpose of making the slab lighter, being the trussed beams are whathave the function of supporting the slab, and using the cement as a wayto connect the slab in the pillars and beams, making them one body. Thisprocess is slow, mainly because of the distribution and assembly of thebeams on the slab, since it is necessary for the worker to distributethe beams and blocks of Styrofoam uniformly over the whole extension ofthe slab. There is also the problem of finishing after the withdrawal ofthe case, since it requires a lot of time and skill of the worker,especially in the finishing stage of the lower part of the slab, whichbesides having a very high degree of difficulty, may require the workerto work in uncomfortable positions, posing risks to your health andphysical integrity in the long and short term.

The interiorities' that more closely approximate the developed object,do not present solution for the construction of slabs as recommended inthis document; one can find anteriority that reveal solutions only ofwalls, because it is a component that should have its weight reduced tothe maximum, however, it must have enough mechanical resistance tosupport the requests that are exposed, providing security for thepeople. Another problem that involves the construction of slabs is thatit needs to thermally and acoustically isolate the lower and upperenvironments from the slab, which is very difficult to achieve with theuse of solid materials such as concrete.

Another problem that may be mentioned is the fact that it is verydifficult to insert new hydraulic and electric pipes into walls andslabs produced in concrete, since there is a need to perform the wallbreaking along the entire pipe length that If desired, a fact that isaggravated when it comes to the breaking of a slab or floor, as it makesthe room or site unusable until the renovation ends.

The fact of filling the profile with concrete generates a variety ofproblems in the constructed wall, such as the fact that concrete isproduced by a mixture of sand, powdered cement and water, and therefore,when drying confined in the profile, it contracts and may cause bubblesand deformations, as it has been poured into a thermoplastic receptacle,and the latter is very easy to deform because it is a flexible material.

In order to solve these problems, this set of form-like facing profilesfor slab, beam and column concreting comprises five specific shapedextrusion profiles which provides an assembly in such a way as to resultin the elimination of all problems. It comprises an extruded profilepreferably in PVC, not limited to this material, comprising the form ofa main beam, with supports for the structuring irons and a profileformed of a main beam and grooves for fixing to the concrete, which fittogether in pairs, by means of fittings, forming a square hollow column,and around this, the casing will be assembled, and after the pouring andhardening of the concrete, in this column the casing can be removed andthe result is a molded and finished column, presenting as lining saidprofile, eliminating subsequent rework.

It also comprises a plate with grooves on one of the faces which isarranged at the base of the slab, on the case, and this plate providesspaces for the light fill arrangement, for example Styrofoam, and forthe iron truss, which forms the beams and lattices, avoiding the use ofpre-cast beams in cement, because when the cement is poured on thepre-molded joist, it can cause in a problem of lack of adhesion, sincethe cement of the joist is already solidified, and due to thecontractions during the solidification of the new cement spillage, thelack of adhesion in the surfaces of the shaft can cause future cracks;said assembly further provides for fittings to a further profile thatthis assembly comprises a filling profile which will replace theStyrofoam block, and with this, we have that the operator needs only tofit the parts coherently, interleaving iron trusses and profiles on saidplate, positioning the iron screen on the slab, and pour the concrete,which significantly reduces the time spent in the construction of theslab, and reduces its weight, so that the slab does not need to be verythick, reducing costs, besides the fact of forming hollow chambers thatincrease the thermal and acoustic insulation and facilitate the openingof channels for passage of new hydraulic and electric pipes, after theslab already is constructed. After removal of the slab from the slab,the lower part will be coated, therefore, only the lower part of theinitially arranged plate will be visible, eliminating the need for anyfinishing at the bottom of the slab.

The figures presented, by way of example and illustration, together withthe description of the profiles and the assembly, will allow a betterunderstanding of the developed object.

FIGS. 1A and 1B show a front cross-sectional view and an isometric view,consecutively, of the profile (100) forming the plate.

FIGS. 2A, 2B and 2C are front profile views (200 and 300) which whenassembled form the columns and sides of the slab.

FIGS. 3A, 3B and 3C are isometric views of the profiles 200 and 300shown in FIGS. 2A, 2B and 2C.

FIGS. 4A to 4F illustrate the assembly combination logic for column ofthe profiles (200 and 300).

FIGS. 5A to 5G are some of the possible variations for columnconstruction resulting from the assembly of the profiles (200 and/or300).

FIGS. 6A and 6B are front and isometric illustrations respectively ofthe filler profile (400) which, when mounted to the profile (100), formsthe filler of the slab. And FIG. 6C shows the cap (410) of the profile(400) which is positioned at the ends of said profile (400).

FIGS. 7A and 7B depict, respectively in side and perspective views, anembodiment of the slab assembly, including the profile (100) forming theslab plate, the profile (200) forming the side of the slab and the slabfiller profile (400), as already previously illustrated in isolation.

Based on the figures presented, the profile set, for support, moldingand finishing, can be visualized in the concrete slab, beam and column,object of this report. The slab is comprised by the assembly of theprofiles (100), which form the main plate, which is the base of saidslab. This profile (100), according to FIGS. 1A and 1B comprises acoupling (101) at one end with the insertion opening aligned with thewall of said profile (100) and a hitch (102) at the opposite end to saidprofile (100), With engaging aperture also opposite the engagement(101); said couplers (101 and 102) provide projections to aid inmounting profile (100 or 200) embedded therein. Each profile (100)provides rods (103) attached at one of their ends to the profile (100),distributed and spaced apart from each other. Said rods (103) mayprovide shoulders (103′) to assist in fixing the profile (400) whichwill subsequently about the said profile (100). Said shoulders (103′)may be arranged in all or some of the rods (103). These shoulders (103′)preferably have the “swallowtail” format type.

The columns are formed from the assembly of the profiles (200 and 300).FIGS. 2A, 2B and 2C illustrate said profiles, where after assembled theyresult in the pre-finished columns. The profile (200) is comprised of aplate (202), which provides claws (204) disposed on one side of saidcross member (202) main defining its inner side; The side opposite thejaws (204) is the outer side of the profile (200); said claws (204) arepreferably positioned with an inclination, which serve to increaseadhesion to the cement after it has been spilled. At one end of the beam(202) there is provided a recess (201), with horizontal engagement andaperture towards the outer side of the profile (200), and at theopposite end a recess (203A) is provided with horizontal engagement andaperture for the Inner side of the profile (200), that is, side oppositethe socket (201), according to FIG. 2A; or a recess (203B) with verticalengagement and opening from the inside of the profile (200), accordingto FIG. 2B. It is also envisaged that the profile (300) which is anothervariation of the profile set for mounting columns in different ways; theprofile (300) includes a crossbar (301) having a central portion inshoulder to the inner part also provides grip (304) in said innerportion, and a recess (302) at one end with coupling upright and openthe (303) at the opposite end with horizontal engagement and aperturewith inlet from the outer side of the profile (300). FIGS. 3A and 3Bshow perspective views of the profiles (200 and 300).

The assembly and its variants are shown in FIGS. 4A to 4F, wherein theinsert (201) engages the recess (203A) to another profile (200) to forman extension wall as FIG. 4A; the socket (201) engages the socket (203B)to form a corner with another profile (200), according to FIG. 4B; andthe insert (201) engages the socket (302) to form a corner with theprofile (300), according to FIG. 4C. The plug (303) of the profile (300)engages the recess (203A) to form an extension of the profile wall(200), as FIG. 4D; The socket (303) engages the socket (203B) to form acorner with a profile (200), according to FIG. 4E; and the insert (303)engages the socket (302) to form a corner with another profile (300),according to FIG. 4E.

FIGS. 5A to 5G are some of the possible variations for columnconstruction as a result of assembling the profiles (200 and/or 300)according to the engagement of the above described recesses, rectangularbeams can be formed in FIGS. 5A, 5F and 5G, In cross-section in FIG. 5B,in “T” in FIG. 5C, square in FIG. 5D, in “L” in FIG. 5E, as well asseveral other possibilities of combinations, being “T” shaped, “U”, withdifferent combinations of profiles (200 and/or 300) resulting innumerous other possible variations not restricted to these figurespresented by way of illustration.

The profile (400) comprises filling a main beam (402), which may havecontinuous straight shape, circular, or may preferably have notches(403) or fillets; (404) has perpendicular and spaced extensions (404)along the crosspiece (402) coincident with the spacing of the rods (103)of the profile (100), and said extensions (404) have female fittings(401), (405) perpendicular to the main cross-member (402) and positionedbetween said main cross-member (402) and the female catch grooves (401),and said profile (400) further provides for claws (406) disposed on itsmain beam (402), which serve to increase adhesion to the cement after ithas been poured. In order to keep the filling space (400) hollow, shownin the figures, this assembly has closed end and can be closed in asingle body profile (400), or providing a lid (410), which is shown in6C, with cross-section supported to engage the end of said filling space(400), preventing the concrete, when poured, fill the empty spacesinside of the filling space (400) and thereby forming hollow chambersinside the filling space (400), increasing the thermal and acousticinsulation and facilitating the opening of channels for the passage ofnew hydraulic and electric pipes, after the slab is already constructed,since the channels remain hollow inside the slab.

For the purpose of understanding and presenting an embodiment of theobject presented here, the process of assembling this new constructivelayout of slab and columns is described. For the construction of acolumn, profiles (200) and/or profiles (300) are used; By way ofillustration, it will be described herein mounting a square simplecolumn using two profiles (200) and two profiles (300), as shown in FIG.5D: first mounts the insert (201) a profile (200) in a fitting (301) ofa profile (300) sequentially, one on top of the other, to form a squarecolumn as shown in FIG. 5D, and then it builds the casing around thiscolumn is positioned irons construction the supports (202) of theprofile (200) and pour the concrete. After the concrete has set, thewood is removed from the casing and the result is a column finished inthermoplastic or other material, but preferably PVC.

The construction of the slab, according to FIGS. 6 and 7, takes placeafter the construction of the columns, then the slab casing isconstructed on the columns and temporary stakes are provided under theslab casing. After constructed casing, the plate is neatly distributed100) horizontally to the slab, and repeats the process, joining theinsert (101) of a plate (100) in the groove (102) of the consecutiveplate (100) until the entire slab has been covered. The framing trusses(T) are then disposed on the extensions (103), preferably on the twofirst ones, and fastened with the clip; then the filler profiles (400)are distributed, by attaching the filler flanges (401) of the fillingprofile (400) into the rods (103) of the plate (100), hence theimportance of the shoulders (103′) to assist in that fastening. In theillustrated case, where the filler profile has caps (410), then the endsof the filler profiles (400) with the said cap (410) must be capped toprevent the yet liquid concrete from filling the empty space of thefilling profile (400) so that it continues hollow after pouring of theconcrete. To form the sides, it connects to the insert (203B) of theprofile (200), the insert (101) of the plate (100), and repeats theprocedure until the entire side of the slab has been circumvented. Theconcrete is then sprayed and waited for the concrete to dry forsubsequent removal of the crate, which, when removed, reveals a finishedslab on its underside, ruling out the need for subsequent finishing. Thematerial of this finish may be in thermoplastic or other similarmaterial, or in the similar group of materials, preferably PVC.

Other embodiments for this system may exit, using the profiles describedherein with profiles combinations (200 and 300) random and varied toform different shapes of columns, setting that has at least one fitting,but which result in a configuration that provides mechanical strengthand also results in the construction of slabs, columns and the like.Those embodiments are also characteristic of this system.

By doing this and using this sequence, we can build low cost slabs,beams and columns, in a short period of time without compromising themechanical strength of the structure, and without the need for finalfinishing after construction.

1. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THECONCRETE OF SLAB, BEAM AND COLUMN used in the lining of the slab, columnand beam, acting as a mold to receive the concrete during theconstruction and with constructive arrangement of the parts that allowsits assembly in a systematic way and with numerous geometric shapes,characterized by the profile (100), which form the main plate, which isthe base of said slab comprising an engagement (101) at one end, with afitting aperture aligned with the wall of said profile (100) and anengagement (102), at the end opposite said profile (100), with engagingaperture also opposite the engagement (101) and each profile (100)provides rods (103) attached at one of their ends to the profile (100),distributed and spaced apart from each other; And a profile (200)comprised by a beam (202), wherein it provides for claws (204) disposedon one of the faces of said main beam (202), defining its inner side andthe side opposite the claws (204) being the outer side of the profile(200) and at one end of the crosspiece (202) there is provided a recess(201), with horizontal engagement and opening towards the outer side ofthe profile (200), and at the opposite end a recess is provided (203A)with horizontal engagement and aperture to the inner side of the profile(200); and a profile (300) formed by a crosspiece (301), with a centralprotruding inner portion, including claws (304), in said inner part, aswell as a recess (302) at one end with vertical engagement and opening(300), and engagement (303) at the opposite end with horizontalengagement and aperture with inlet from the outer side of the profile(300); and the filling profile (400) comprising a main crosspiece (402)with projections (404) perpendicular to the crosspiece (402) spacedalong the crosspiece (402) coincident with the spacing of the rods (103)of the profile (100), and said extensions have female fittings (401) attheir end so as to be engaged in said rods (103), and provides asecondary crosspiece (405) perpendicular to the main crosspiece (402)and positioned between said main crosspiece (402) and female fittings(404), and said profile (400) further provides claws (406) disposed onits main beam (402)
 2. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING ANDFINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1,characterized by said engagement (101 and 102) providing shoulders. 3.ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETESLAB, BEAM AND COLUMN, according to claim 1, characterized in that therods (103) provide projections (103′) to assist in securing the femalefittings (401) of the profile (400).
 4. ASSEMBLY OF PROFILES FORSUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN,according to claim 1, characterized in that the shoulders (103′) can bearranged on all or some of the rods (103).
 5. ASSEMBLY OF PROFILES FORSUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN,according to claim 1, characterized in that the shoulders (103′) havethe “swallowtail” shape.
 6. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDINGAND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1,characterized by claws (204) or (304) or (406) to be positionedinclined.
 7. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHINGTHE CONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterizedby the fitting (203A) being replaced by a fitting (203B) with a verticalengagement and an inside opening in the profile (200).
 8. ASSEMBLY OFPROFILES FOR SUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAMAND COLUMN, according to claim 1, characterized by the female fittings(401) having inner shoulders.
 9. ASSEMBLY OF PROFILES FOR SUSTAINING,MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according toclaim 1, characterized by the inner shoulders are of the swallowtailtype.
 10. ASSEMBLY OF PROFILES FOR SUSTAINING, MOLDING AND FINISHING THECONCRETE SLAB, BEAM AND COLUMN, according to claim 1, characterized bythe end of the profile (400) being closed.
 11. ASSEMBLY OF PROFILES FORSUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN,according to claim 1, characterized by the end of the profile (400)being closed by a cap (410), with a compatible cross section to befitted at the end of the profile (400).
 12. ASSEMBLY OF PROFILES FORSUSTAINING, MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN,according to claim 1, characterized by the profile (400) being shapedwith chamfers (403) or fillets.
 13. ASSEMBLY OF PROFILES FOR SUSTAINING,MOLDING AND FINISHING THE CONCRETE SLAB, BEAM AND COLUMN, according toclaim 1, characterized by the fitting (201) being compatible to engagethe fitting (203A) of another profile (200); And the fitting (201) iscompatible to engage the fitting (203B) to form a corner with anotherprofile (200); And the fitting (201) is compatible to engage the fitting(302) so as to form a corner with the profile (300); And the fitting(303) of the profile 300 is compatible to engage the fitting (203A) toform a wall extension with the profile (200), and the fitting (303) iscompatible to engage the fitting (203B), so as to form a corner with aprofile (200), and the fitting (303) is compatible to engage the fitting(302) so as to form a corner with another fitting (300); And the fitting(203B) of the profile (200) is compatible so as to engage the fitting(101) of the plate (100) forming the side of the slab.